Leached Cutter And Method For Improving The Leaching Process

ABSTRACT

A method to leach a component that includes a polycrystalline structure. The method includes obtaining the component having the polycrystalline structure. The polycrystalline structure includes catalyst material deposited therein. The method also includes performing a leaching process on the polycrystalline structure to an intermediate leaching depth. The leaching process removes at least a portion of the catalyst material from the polycrystalline structure and forms one or more by-product materials deposited therein. The method also includes performing a cleaning process on the polycrystalline structure, which removes at least a portion of the by-product materials. The leaching process and the cleaning process are iteratively continued until the intermediate leaching depth reaches a desired leaching depth, both of which are measured from one end of the polycrystalline structure. The desired leaching depth is greater than at least one intermediate leaching depth.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/428,635, entitled “Method to Improve the Leaching Process,” filedMar. 23, 2012, and is incorporated in its entirety herein.

The present application is related to U.S. patent application Ser. No.13/401,452, entitled “Method to Improve the Performance of a LeachedCutter” and filed on Feb. 21, 2012, U.S. patent application Ser. No.13/401,188, entitled “Use of Capacitance to Analyze PolycrystallineDiamond” and filed on Feb. 21, 2012, and U.S. patent application Ser.No. 13/401,335, entitled “Use of Capacitance and Eddy Currents toAnalyze Polycrystalline Diamond” and filed on Feb. 21, 2012, which areall incorporated by reference herein.

TECHNICAL FIELD

The present invention is directed generally to methods of leachingcomponents having a polycrystalline structure. More particularly, thepresent invention is directed to methods of leaching components having apolycrystalline structure that include one or more cycles of a leachingprocess and a cleaning process, where the leaching process removes atleast a portion of the catalyst materials present within thepolycrystalline structure and the cleaning process removes at least aportion of the by-product materials formed during the leaching processand present within the polycrystalline structure.

BACKGROUND

Polycrystalline diamond compacts (“PDC”) have been used in industrialapplications, including rock drilling applications and metal machiningapplications. Such compacts have demonstrated advantages over some othertypes of cutting elements, such as better wear resistance and impactresistance. The PDC can be formed by sintering individual diamondparticles together under the high pressure and high temperature (“HPHT”)conditions referred to as the “diamond stable region,” which istypically above forty kilobars and between 1,200 degrees Celsius and2,000 degrees Celsius, in the presence of a catalyst/solvent whichpromotes diamond-diamond bonding. Some examples of catalyst/solvents forsintered diamond compacts are cobalt, nickel, iron, and other Group VIIImetals. PDCs usually have a diamond content greater than seventy percentby volume, with about eighty percent to about ninety-eight percent beingtypical. An unbacked PDC can be mechanically bonded to a tool (notshown), according to one example. Alternatively, the PDC is bonded to asubstrate, thereby forming a PDC cutter, which is typically insertablewithin, or mounted to, a downhole tool (not shown), such as a drill bitor a reamer.

FIG. 1 shows a side view of a PDC cutter 100 having a polycrystallinediamond (“PCD”) cutting table 110, or compact, in accordance with theprior art. Although a PCD cutting table 110 is described in theexemplary embodiment, other types of cutting tables, includingpolycrystalline boron nitride (“PCBN”) compacts, are used in alternativetypes of cutters. Referring to FIG. 1, the PDC cutter 100 typicallyincludes the PCD cutting table 110 and a substrate 150 that is coupledto the PCD cutting table 110. The PCD cutting table 110 is about onehundred thousandths of an inch (2.5 millimeters) thick; however, thethickness is variable depending upon the application in which the PCDcutting table 110 is to be used.

The substrate 150 includes a top surface 152, a bottom surface 154, anda substrate outer wall 156 that extends from the circumference of thetop surface 152 to the circumference of the bottom surface 154. The PCDcutting table 110 includes a cutting surface 112, an opposing surface114, and a PCD cutting table outer wall 116 that extends from thecircumference of the cutting surface 112 to the circumference of theopposing surface 114. The opposing surface 114 of the PCD cutting table110 is coupled to the top surface 152 of the substrate 150. Typically,the PCD cutting table 110 is coupled to the substrate 150 using a highpressure and high temperature (“HPHT”) press. However, other methodsknown to people having ordinary skill in the art can be used to couplethe PCD cutting table 110 to the substrate 150. In one embodiment, uponcoupling the PCD cutting table 110 to the substrate 150, the cuttingsurface 112 of the PCD cutting table 110 is substantially parallel tothe substrate's bottom surface 154. Additionally, the PDC cutter 100 hasbeen illustrated as having a right circular cylindrical shape; however,the PDC cutter 100 is shaped into other geometric or non-geometricshapes in other exemplary embodiments. In certain exemplary embodiments,the opposing surface 114 and the top surface 152 are substantiallyplanar; however, the opposing surface 114 and the top surface 152 isnon-planar in other exemplary embodiments. Additionally, according tosome exemplary embodiments, a bevel (not shown) is formed around atleast a portion of the circumference of the cutting surface 112.

According to one example, the PDC cutter 100 is formed by independentlyforming the PCD cutting table 110 and the substrate 150, and thereafterbonding the PCD cutting table 110 to the substrate 150. Alternatively,the substrate 150 is initially formed and the PCD cutting table 110 issubsequently formed on the top surface 152 of the substrate 150 byplacing polycrystalline diamond powder onto the top surface 152 andsubjecting the polycrystalline diamond powder and the substrate 150 to ahigh temperature and high pressure process. Alternatively, the substrate150 and the PCD cutting table 110 are formed and bonded together atabout the same time. Although a few methods of forming the PDC cutter100 have been briefly mentioned, other methods known to people havingordinary skill in the art can be used.

According to one example for forming the PDC cutter 100, the PCD cuttingtable 110 is formed and bonded to the substrate 150 by subjecting alayer of diamond powder and a mixture of tungsten carbide and cobaltpowders to HPHT conditions. The cobalt is typically mixed with tungstencarbide and positioned where the substrate 150 is to be formed. Thediamond powder is placed on top of the cobalt and tungsten carbidemixture and positioned where the PCD cutting table 110 is to be formed.The entire powder mixture is then subjected to HPHT conditions so thatthe cobalt melts and facilitates the cementing, or binding, of thetungsten carbide to form the substrate 150. The melted cobalt alsodiffuses, or infiltrates, into the diamond powder and acts as a catalystfor synthesizing diamond bonds and forming the PCD cutting table 110.Thus, the cobalt acts as both a binder for cementing the tungstencarbide and as a catalyst/solvent for sintering the diamond powder toform diamond-diamond bonds. The cobalt also facilitates in formingstrong bonds between the PCD cutting table 110 and the cemented tungstencarbide substrate 150.

Cobalt has been a preferred constituent of the PDC manufacturingprocess. Traditional PDC manufacturing processes use cobalt as thebinder material for forming the substrate 150 and also as the catalystmaterial for diamond synthesis because of the large body of knowledgerelated to using cobalt in these processes. The synergy between thelarge bodies of knowledge and the needs of the process have led to usingcobalt as both the binder material and the catalyst material. However,as is known in the art, alternative metals, such as iron, nickel,chromium, manganese, and tantalum, and other suitable materials, can beused as a catalyst for diamond synthesis. When using these alternativematerials as a catalyst for diamond synthesis to form the PCD cuttingtable 110, cobalt, or some other material such as nickel chrome or iron,is typically used as the binder material for cementing the tungstencarbide to form the substrate 150. Although some materials, such astungsten carbide and cobalt, have been provided as examples, othermaterials known to people having ordinary skill in the art can be usedto form the substrate 150, the PCD cutting table 110, and form bondsbetween the substrate 150 and the PCD cutting table 110.

FIG. 2 is a schematic microstructural view of the PCD cutting table 110of FIG. 1 in accordance with the prior art. Referring to FIGS. 1 and 2,the PCD cutting table 110 has diamond particles 210 bonded to otherdiamond particles 210, one or more interstitial spaces 212 formedbetween the diamond particles 210, and cobalt 214 deposited within theinterstitial spaces 212. During the sintering process, the interstitialspaces 212, or voids, are formed between the carbon-carbon bonds and arelocated between the diamond particles 210. The diffusion of cobalt 214into the diamond powder results in cobalt 214 being deposited withinthese interstitial spaces 212 that are formed within the PCD cuttingtable 110 during the sintering process.

Once the PCD cutting table 110 is formed and placed into operation, thePCD cutting table 110 is known to wear quickly when the temperaturereaches a critical temperature. This critical temperature is about 750degrees Celsius and is reached when the PCD cutting table 110 is cuttingrock formations or other known materials. The high rate of wear isbelieved to be caused by the differences in the thermal expansion ratebetween the diamond particles 210 and the cobalt 214 and also by thechemical reaction, or graphitization, that occurs between cobalt 214 andthe diamond particles 210. The coefficient of thermal expansion for thediamond particles 210 is about 1.0×10⁻⁶ millimeters⁻¹×Kelvin⁻¹(“mm⁻¹K⁻¹”), while the coefficient of thermal expansion for the cobalt214 is about 13.0×10⁻⁶ mm⁻¹ K⁻¹. Thus, the cobalt 214 expands muchfaster than the diamond particles 210 at temperatures above thiscritical temperature, thereby making the bonds between the diamondparticles 210 unstable. The PCD cutting table 110 becomes thermallydegraded at temperatures above about 750 degrees Celsius and its cuttingefficiency deteriorates significantly.

Efforts have been made to slow the wear of the PCD cutting table 110 atthese high temperatures. These efforts include performing conventionalacid leaching processes of the PCD cutting table 110 which removes someof the cobalt 214, or catalyst material, from the interstitial spaces212. Conventional leaching processes involve the presence of an acidsolution (not shown) which reacts with the cobalt 214, or otherbinder/catalyst material, that is deposited within the interstitialspaces 212 of the PCD cutting table 110. These acid solutions typicallyconsist of highly concentrated solutions of hydrofluoric acid (HF),nitric acid (HNO₃), and/or sulfuric acid (H₂SO₄) and are subjected todifferent temperature and pressure conditions. According to one exampleof a conventional leaching process, the PDC cutter 100 is placed withinan acid solution such that at least a portion of the PCD cutting table110 is submerged within the acid solution. The acid solution reacts withthe cobalt 214, or other binder/catalyst material, along the outersurfaces of the PCD cutting table 110. The acid solution slowly movesinwardly within the interior of the PCD cutting table 110 and continuesto react with the cobalt 214. During the reaction, one or moreby-product materials 398 (FIG. 3) are formed. These by-product materials398 (FIG. 3) are usually water soluble and dissolve within the solution;however, these by-product materials 398 (FIG. 3) become trapped in theinterstitial spaces 21 when the concentration becomes too high and theyprecipitate out of solution. As more by-product material 398 (FIG. 3)become trapped within the PCD cutting table 110, the acid solution movesinwardly at even a slower rate; and hence, the rate of leaching slowsdown considerably within these conventional leaching processes. For thisreason, a tradeoff occurs between conventional leaching process durationand the desired leaching depth, wherein costs increase as theconventional leaching process duration increases. Thus, the leachingdepth is typically about 0.2 millimeters, which takes about days toachieve this depth. However, the leached depth can be more or lessdepending upon the PCD cutting table 110 requirements and/or the costconstraints. The removal of cobalt 214 alleviates the issues created dueto the differences in the thermal expansion rate between the diamondparticles 210 and the cobalt 214 and due to graphitization. Although ithas been described that conventional leaching processes are used toremove at least some of the catalyst 214, other leaching processes orcatalyst removal processes can be used to remove at least some of thecatalyst 214 from the interstitial spaces 212.

FIG. 3 shows a cross-section view of a leached PDC cutter 300 having aPCD cutting table 310 that has been at least partially leached inaccordance with the prior art. Referring to FIG. 3, the PDC cutter 300includes the PCD cutting table 310 coupled to a substrate 350. Thesubstrate 350 is similar to substrate 150 (FIG. 1) and is not describedagain for the sake of brevity. The substrate 350 includes a top surface365, a bottom surface 364, and a substrate outer wall 366 extending fromthe perimeter of the top surface 365 to the perimeter of the bottomsurface 364. The PCD cutting table 310 is similar to the PCD cuttingtable 110 (FIG. 1), but includes a leached layer 354 and an unleachedlayer 356. The leached layer 354 extends from the cutting surface 312,which is similar to the cutting surface 112 (FIG. 1), towards anopposing surface 314, which is similar to the opposing surface 114 (FIG.1). In the leached layer 354, at least a portion of the cobalt 214 hasbeen removed from within the interstitial spaces 212 (FIG. 2) using atleast one leaching process mentioned above. Thus, the leached layer 354has been leached to a desired depth 353. However, as previouslymentioned above, one or more by-product materials 398 are formed anddeposited within some of the interstitial spaces 212 (FIG. 2) in theleached layer 354 during the leaching process. These by-productmaterials 398 are chemical by-products, or catalyst salts, of thedissolution reaction which are trapped within the open porosity of theinterstitial spaces 212 (FIG. 2) during and/or after the dissolutionprocess has been completed. The unleached layer 356 is similar to thePCD cutting table 150 (FIG. 1) and extends from the end of the leachedlayer 354 to the opposing surface 314. In the unleached layer 356, thecobalt 214 (FIG. 2) remains within the interstitial spaces 212 (FIG. 2)and has not been removed. Although a boundary line 355 is formed betweenthe leached layer 354 and the unleached layer 356 and is depicted asbeing substantially linear, the boundary line 355 can be non- linear.

The leached PDC cutters 300 are leached to different desired depths 353and how deep the cutter 300 has been leached has an effect on theperformance of the cutter 300. As previously mentioned, the conventionalleaching process is very slow, and thus, leached PDC cutters 300 thathave been leached using the conventional leaching process become moreexpensive as the leaching depth increases. The cost of producing theleached PDC cutters 300 can be decreased if the rate of leaching were toincrease. Further, the presence of by-product materials 398 within theleached layer 354 negatively impacts the performance of the leached PDCcutter 300.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and aspects of the invention are bestunderstood with reference to the following description of certainexemplary embodiments, when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 shows a side view of a PDC cutter having a PCD cutting table inaccordance with the prior art;

FIG. 2 is a schematic microstructural view of the PCD cutting table ofFIG. 1 in accordance with the prior art;

FIG. 3 shows a cross-sectional view of a leached PDC cutter having a PCDcutting table that has been at least partially leached in accordancewith the prior art;

FIG. 4 is a flowchart depicting a leaching method in accordance with anexemplary embodiment of the present invention;

FIG. 5 shows a cross-sectional view of an intermediately leached PDCcutter in accordance with an exemplary embodiment of the presentinvention;

FIG. 6 shows a cross-sectional view of the intermediately cleanedleached PDC cutter in accordance with an exemplary embodiment of thepresent invention;

FIG. 7 is a cross-sectional view of a by-products removal apparatus inaccordance with an exemplary embodiment;

FIG. 8 is a cross-sectional view of a by-products removal apparatus inaccordance with another exemplary embodiment;

FIG. 9 is a cross-sectional view of a by-products removal apparatus inaccordance with another exemplary embodiment;

FIG. 10 is a cross-sectional view of a by-products removal apparatus inaccordance with another exemplary embodiment;

FIG. 11 is a flowchart depicting a by-product materials removalverification method in accordance with an exemplary embodiment of thepresent invention;

FIG. 12 is a schematic view of a capacitance measuring system inaccordance to one exemplary embodiment of the present invention;

FIG. 13 is a schematic view of a capacitance measuring system inaccordance to another exemplary embodiment of the present invention;

FIG. 14 is a data scattering chart that shows the measured capacitancevalues for a plurality of intermediately leached and/or intermediatelycleaned cutters at different cleaning cycles according to an exemplaryembodiment; and

FIG. 15 shows a cross-sectional view of the cleaned leached PDC cutterhaving a PCD cutting table that has been leached to the desired leachingdepth in accordance with an exemplary embodiment.

The drawings illustrate only exemplary embodiments of the invention andare therefore not to be considered limiting of its scope, as theinvention may admit to other equally effective embodiments.

BRIEF DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present invention is directed generally to methods of leachingcomponents having a polycrystalline structure. More particularly, thepresent invention is directed to methods of leaching components having apolycrystalline structure that include one or more cycles of a leachingprocess and a cleaning process, where the leaching process removes atleast a portion of the catalyst materials present within thepolycrystalline structure and the cleaning process removes at least aportion of the by-product materials formed during the leaching processand also present within the polycrystalline structure. Each additionalleaching process and cleaning process removes catalyst materials andby-product materials, respectively, from deeper within thepolycrystalline structure. The cleaning process allows the next leachingprocess to perform at a faster rate than if the cleaning process did nothappen. Although the description of exemplary embodiments is providedbelow in conjunction with a polycrystalline diamond compact (“PDC”)cutter, alternate embodiments of the invention may be applicable toother types of cutters or components including, but not limited to,polycrystalline boron nitride (“PCBN”) cutters or PCBN compacts. Aspreviously mentioned, the compact is mountable to a substrate to form acutter or is mountable directly to a tool for performing cuttingprocesses. The invention is better understood by reading the followingdescription of non-limiting, exemplary embodiments with reference to theattached drawings, wherein like parts of each of the figures areidentified by like reference characters, and which are briefly describedas follows.

FIG. 4 is a flowchart depicting a leaching method 400 in accordance withan exemplary embodiment of the present invention. Although FIG. 4 showsa series of steps depicted in a certain order, the order of one or moresteps can be rearranged, combined into fewer steps, and/or separatedinto more steps than that shown in other exemplary embodiments.Referring to FIG. 4, the leaching method 400 begins at step 410. Uponstarting at step 410, the leaching method 400 proceeds to step 420. Atstep 420, one or more PDC cutters are obtained. According to certainexemplary embodiments, each PDC cutter includes a polycrystallinestructure having a first end and a second end. The polycrystallinestructure also includes one or more catalyst materials depositedtherein. These PDC cutters have been described above in detail withrespect to FIGS. 1 and 2 and therefore are not described again for thesake of brevity.

The leaching method 400 proceeds to step 430. At step 430, a leachingprocess is performed on the polycrystalline structure of one or more PDCcutters. The leaching process removes at least a portion of the catalystmaterials from a leached portion of the polycrystalline structure andforms one or more by-product materials. The leached portion extends fromthe first end to a leaching depth end, where the leaching depth end isbetween the first end and the second end. At least a portion of theby-product materials is deposited within the leached portion. Theleaching process continues until the rate of leaching decreases below adesired leaching threshold, which is determined by a user.Alternatively, the leaching process continues for a desired leachingperiod, which also is determined by the user. The desired leachingperiod ranges from a few minutes to several hours or days, if desired.Hence, at step 430, an intermediately leached PDC cutter 500 (FIG. 5) isformed.

FIG. 5 shows a cross-sectional view of the intermediately leached PDCcutter 500 in accordance with an exemplary embodiment of the presentinvention. Referring to FIG. 5, the intermediately leached PDC cutter500 includes the PCD cutting table 510, which is a polycrystallinestructure, coupled to the substrate 350. The substrate 350 has beenpreviously described with respect to FIG. 3 and is not described againfor the sake of brevity. The PCD cutting table 510 is similar to the PCDcutting table 310 (FIG. 3), but includes a leached layer 554 and anunleached layer 556 having different depths, or thicknesses, than theleached layer 354 (FIG. 3) and the unleached layer 356 (FIG. 3),respectively, of the leached PDC cutter 300 (FIG. 3). The leached layer554 also is referred to herein as a leached portion 554. Specifically,the leached portion 554 has a smaller depth, or smaller thickness, thanleached layer 354 (FIG. 3). Also, the unleached layer 556 has a greaterdepth, or greater thickness, than the unleached layer 356 (FIG. 3).Hence, the depth of the leached portion 554, or an intermediate leachingdepth 553 according to some exemplary embodiments, within theintermediately leached PDC cutter 500 has not yet reached the leachingdepth 353 (FIG. 3), or desired leaching depth, of the leached PDC cutter300 (FIG. 3). The intermediately leached PDC cutter 500 is formed usinga leaching process for a shorter time period than when forming theleached PDC cutter 300 (FIG. 3).

The leached portion 554 extends from the cutting surface 512, or firstend, which is similar to the cutting surface 312 (FIG. 3), towards anopposing surface 514, or second end, which is similar to the opposingsurface 314 (FIG. 3). In the leached portion 554, at least a portion ofthe cobalt 214 has been removed from within the interstitial spaces 212(FIG. 2) using at least one leaching process, which is described infurther detail below. Thus, the leached portion 554 has been leached tothe intermediate leaching depth 553. However, as previously mentionedabove, one or more by-product materials 398 are formed and depositedwithin some of the interstitial spaces 212 (FIG. 2) in the leachedportion 554 during the leaching process. These by-product materials 398are chemical by-products, or catalyst salts, of the dissolution reactionwhich are trapped within the open porosity of the interstitial spaces212 (FIG. 2) during and/or after the dissolution process has beencompleted. Further, these trapped by-product materials 398 cause theleaching rate to decrease as the concentration of by-product materials398 within the leached portion 554 increases. The unleached layer 556 iscomposed similarly as the PCD cutting table 150 (FIG. 1) and extendsfrom a leaching depth end 555 of the leached portion 554 to the opposingsurface 514. In the unleached layer 556, the cobalt 214 remains withinthe interstitial spaces 212 (FIG. 2) and has not been removed. Althoughthe leaching depth end 555 is depicted as being substantially linear,the leaching depth end 555 can be non-linear.

The leaching process is performed a first time and removes at least aportion of the catalyst materials 214 from the PDC cutter 100 (FIG. 1)to form the intermediately leached PDC cutter 500. The leaching processis performed using a catalyst removal apparatus according to someexemplary embodiments. There are several catalyst removal apparatusesthat are known or not yet known to people having ordinary skill in theart which are applicable to the present disclosure. For example, onesuch catalyst removal apparatus (not shown) includes a tank (not shown),or tray, having a cavity (not shown) formed therein and an acid solution(not shown) placed within the cavity. This apparatus is operated usingthe conventional leaching process described above according to someexemplary embodiments and is not repeated again for the sake of brevity.Other examples of the catalyst removal apparatus include, but are notlimited to, at least those apparatuses which utilize acid leachingprocesses and/or electrochemical removal processes.

Referring back to FIG. 4, the leaching method 400 proceeds to step 440.At step 440, a cleaning process is performed on the leached portion 554(FIG. 5) of the intermediately leached PDC cutter 500 (FIG. 5). Thecleaning process removes at least a portion of the by-product materials398 (FIG. 5) from the leached portion 554 (FIG. 5) of thepolycrystalline structure 510 (FIG. 5). At step 440, an intermediatelycleaned leached PDC cutter 600 (FIG. 6) is formed from theintermediately leached PDC cutter 500 (FIG. 5) where at least some ofthe by-product materials 398 (FIG. 5) has been removed.

FIG. 6 shows a cross-sectional view of the intermediately cleanedleached PDC cutter 600 in accordance with an exemplary embodiment of thepresent invention. Referring to FIG. 6, the intermediately cleanedleached PDC cutter 600 includes the PCD cutting table 610 coupled to thesubstrate 350. The substrate 350 has been previously described withrespect to FIG. 3 and is not described again for the sake of brevity.The PCD cutting table 610 is similar to the PCD cutting table 510 (FIG.5), but includes a cleaned leached portion 654 that has had at least aportion of the by-product materials 398 removed from the leached portion554 (FIG. 5). Thus, PCD cutting table 610 includes the cleaned leachedportion 654 and the unleached layer 556 which is disposed between thecleaned leached portion 654 and the substrate 350. The cleaned leachedportion 654 extends from the cutting surface 512, which has beendescribed above with respect to FIG. 5, towards the opposing surface514, which also has been described with respect to FIG. 5. In thecleaned leached portion 654, at least a portion of the cobalt 214 hasbeen removed from within the interstitial spaces 212 (FIG. 2) using atleast one leaching process mentioned above when compared to the PCDcutting table 110 (FIG. 1). Thus, the cleaned leached portion 654 hasbeen leached to the intermediate leaching depth 553. However, aspreviously mentioned above, one or more by-product materials 398 wereformed and deposited within some of the interstitial spaces 212 (FIG. 2)in the leached portion 554 (FIG. 5) during the leaching process.However, at least a portion of these by-product materials 398 areremoved from the leached portion 554 (FIG. 5), thereby forming cleanedleached portion 654 of the intermediately cleaned leached PDC cutter600. The process of removing the by-product materials 398 from theleached portion 554 (FIG. 5) is described in further detail below. Aspreviously mentioned, these by-product materials 398 are chemicalby-products, or catalyst salts, of the dissolution reaction which aretrapped within the open porosity of the interstitial spaces 212 (FIG. 2)after the dissolution process has been completed. The unleached layer556 has been previously described with respect to FIG. 5 and thereforeis not repeated for the sake of brevity.

The cleaning process is performed a first time and removes theby-product materials from the leached portion 554 (FIG. 5) of theintermediately leached PDC cutter 500 (FIG. 5) to form theintermediately cleaned leached PDC cutter 600. The cleaning processcontinues until a desired cleaning level is determined, which isdetermined by a user. Alternatively, the cleaning process continues fora desired cleaning period, which also is determined by the user. Thedesired cleaning period ranges from a few minutes to several hours ordays, if desired. The cleaning process is performed using a by-productsremoval apparatus according to some exemplary embodiments. There areseveral by-products removal apparatuses that are known or not yet knownto people having ordinary skill in the art which are applicable to thepresent disclosure. For example, FIG. 7 is a cross-sectional view of aby-products removal apparatus 700 in accordance with an exemplaryembodiment. Referring to FIG. 7, the by-products removal apparatus 700includes the intermediately leached PDC cutter 500, a covering 710, animmersion tank 720, a cleaning fluid 730, a transducer 750, and at leastone power source 760. According to certain exemplary embodiments, thecovering 710 is optional. As the cleaning fluid 730 becomes increasinglymore basic or more acidic, the use of the covering 710 becomes lessoptional.

The intermediately leached PDC cutter 500 has been previously describedwith respect to FIG. 5 and therefore is not described again in detail.Referring to FIGS. 5 and 7, the intermediately leached PDC cutter 500includes the PCD cutting table 510 and the substrate 350 that is coupledto the PCD cutting table 510. As previously mentioned, the PCD cuttingtable 510 includes the leached portion 554 and the unleached layer 556disposed between the leached portion 554 and the substrate 350. Theleached portion 554 has at least a portion of the catalyst material 214removed from therein using a known leaching process or some otherprocess for removing the catalyst material 214. The leached portion 554also includes by-product materials 398, which has been discussed indetail above and is not repeated again for the sake of brevity. Theunleached layer 556 includes catalyst material 214 which has not beenremoved. Although the PCD cutting table 510 is used in the exemplaryembodiment, other types of cutting tables, including PCBN compacts, areused in alternative exemplary embodiments. The PCD cutting table 510 isabout one hundred thousandths of an inch (2.5 millimeters) thick;however, the thickness is variable depending upon the application inwhich the PCD cutting table 510 is to be used. Also, although theintermediately leached PDC cutter 500 is described as being used in theby-products removal apparatus 700, the leached PDC cutter 300 (FIG. 3)can be used in certain exemplary embodiments.

Referring to FIGS. 5 and 7 and as previously mentioned, the by-productsremoval apparatus 700 includes the covering 710, which is optional. Incertain exemplary embodiments, the covering 710 is annularly shaped andforms a channel 712 therein. The covering 710 surrounds at least aportion of a substrate outer wall 366 extending from about the perimeterof a top surface 365 of the substrate 350 towards a bottom surface 364of the substrate 350. The bottom surface 364, the top surface 365, andthe substrate outer wall 366 of substrate 350 are similar to the bottomsurface 154 (FIG. 1), the top surface 152 (FIG. 1), and the substrateouter wall 156 (FIG. 1), respectively, of the substrate 150 (FIG. 1) andis not repeated herein again. In some exemplary embodiments, a portionof the covering 710 also surrounds a portion of the perimeter of a PCDcutting table outer wall 576 extending from the perimeter of theopposing surface 514 towards the cutting surface 512. The PCD cuttingtable outer wall 576 of the intermediately leached PDC cutter 500 issimilar to the PCD cutting table outer wall 116 (FIG. 1) of the PDCcutter 100 (FIG. 1) and therefore is not repeated again. Thus, thecutting surface 512 and at least a portion of the PCD cutting tableouter wall 576 is exposed and not concealed by the covering 710 incertain exemplary embodiments. The covering 710 is fabricated usingepoxy resin; however, other suitable materials, such as a plastic,porcelain, or Teflon®, can be used without departing from the scope andspirit of the exemplary embodiment. In some exemplary embodiments, thecovering 710 is positioned around at least a portion of theintermediately leached PDC cutter 500 by inserting the intermediatelyleached PDC cutter 500 through the channel 712 of the covering 710. Thecovering 710 is friction fitted to the intermediately leached PDC cutter500 in some exemplary embodiments, while in other exemplary embodiments,the covering 710 is securely positioned by placing an o-ring (notshown), or other suitable known device, around the intermediatelyleached PDC cutter 500 and inserting the intermediately leached PDCcutter 500 and the coupled o-ring into the covering 710 so that theo-ring is inserted into a circumferential groove (not shown) formedwithin the internal surface of the covering 710. In an alternativeexemplary embodiment, the covering 710 is circumferentially applied ontothe substrate outer wall 366 and/or the PCD cutting table outer wall 576of the intermediately leached PDC cutter 500. Although some methods forsecuring the covering 710 to the intermediately leached PDC cutter 500have been described, other methods known to people having ordinary skillin the art can be used without departing from the scope and spirit ofthe exemplary embodiment. The covering 710 protects the surface of thesubstrate outer wall 366 and/or at least a portion of the PCD cuttingtable outer wall 576 to which it is applied from being exposed to thecleaning fluid 730, which is discussed in further detail below.

The immersion tank 720 includes a base 722 and a surrounding wall 724extending substantially perpendicular around the perimeter of the base722, thereby forming a cavity 726 therein. According to certainexemplary embodiments, the base 722 is substantially planar; however,the base 722 is non-planar in other exemplary embodiments. Also inalternative exemplary embodiments, the surrounding wall 724 isnon-perpendicular to the base 722. Also, the immersion tank 720 isformed having a rectangular shape. Alternatively, the immersion tank 720is formed having any other geometric shape or non-geometric shape. Insome exemplary embodiments, the immersion tank 720 is fabricated using aplastic material; however, other suitable materials, such as metal,metal alloys, or glass, are used in other exemplary embodiments. Thematerial used to fabricate the immersion tank 720 typically does notreact with the cleaning fluid 730. According to some exemplaryembodiments, a removable lid (not shown) is used to enclose at least theintermediately leached PDC cutter 500 and the transducer 750, therebyproviding a seal to the cavity 730. Hence, the removable lid and theimmersion tank 720 together form a pressurized vessel (not shown). Inthese exemplary embodiments, the power source 760 can be coupled to thelid, can be positioned outside the pressurized vessel as long as thepressurized vessel provides a port (not shown) to electrically couplethe power source 760 to the transducer 750, or can be integrated withthe transducer 750.

The cleaning fluid 730 is placed within the cavity 726 of the immersiontank 720 and filled to a depth of at least the thickness of the PCDcutting table 710. The cleaning fluid 730 is de-ionized water in theexemplary embodiment. The by-product materials 398 that clog the PCDopen porosity is dissolvable in the cleaning fluid 730. According tosome exemplary embodiments, one or more additional chemicals are addedto the de-ionized water to form the cleaning fluid 730 and increase therate at which the by-product materials 398 are dissolved into thecleaning fluid 730. These additional chemicals are based upon thecomposition of the by-product materials 398. Some examples of theseadditional chemicals are acetic acid and/or formic acid to make thesolution slightly acidic or ammonia to make the solution slightly basic.However, in other exemplary embodiments, any fluid or solution that isable to dissolve and/or react with the by-product materials 398 can beused for the cleaning fluid 730 in lieu of, or in addition to, thede-ionized water. According to some exemplary embodiments, the cleaningfluid 730 is heated to increase the rate at which the by-productmaterials 398 are dissolved into the cleaning fluid 730 and henceaccelerate the cleaning process. The temperature of the cleaning fluid730 can be heated up to 100° C. in the immersion tank 720 or somesimilar type tank. However, the temperature of the cleaning fluid 730can be heated higher than 100° C. in the pressurized vessel mentionedabove, thereby avoiding or reducing boiling of the cleaning fluid 730.

The transducer 750 is coupled to the intermediately leached PDC cutter500 according to some exemplary embodiments. According to some exemplaryembodiments, a portion of the transducer 750 is coupled to the bottomsurface 364 of the intermediately leached PDC cutter 500; however thetransducer 750 can be coupled to a portion of the substrate outer wall366 in other exemplary embodiments. Alternatively, the transducer 750 iscoupled to a portion of the immersion tank 720 or positioned within thecleaning fluid 730, thereby producing vibrations which propagate throughthe cleaning fluid 730 and into the intermediately leached PDC cutter500. The transducer 750 also is coupled to a power source 760 using anelectrical wire 761. The transducer 750 converts electric currentsupplied from the power source 760 into vibrations that are propagatedthrough the intermediately leached PDC cutter 500. The transducer 750 isshaped into a cylindrical shape and has a circumference sizedapproximately similarly to the circumference of the bottom surface 364.However, the shape and size of the transducer 750 varies in otherexemplary embodiments. The transducer 750 is a piezoelectric transducer;however, the transducer 750 is a magnetostrictive transducer in otherexemplary embodiments. The transducer 750 operates at a frequency ofabout forty kilohertz (kHz) in some exemplary embodiments. In otherexemplary embodiments, the transducer 750 operates at a frequencyranging from about twenty kHz to about fifty kHz; yet, in still otherexemplary embodiments, the operating frequency is higher or lower thanthe provided range. The transducer 750 supplies ultrasonic vibrations755 which propagate through the intermediately leached PDC cutter 500and facilitate the by-product materials 398 removal from theinterstitial spaces 212 (FIG. 2) formed within the PCD cutting table510, which is further described below.

Once the by-products removal apparatus 700 has been set up and at leasta portion of the PCD cutting table 510 is immersed into the cleaningfluid 730, the cleaning fluid 730 penetrates into the leached portion554 and dissolves the by-product materials 398 that are clogging the PCDopen porosity. The by-product materials 398 are highly soluble in thecleaning fluid 730. In certain exemplary embodiments, the transducer 750and the power source 760 are included in the by-product removalapparatus 700. The power source 760 is turned “on” to facilitate removalof the by-product materials 398 from the PCD cutting table 510 back intothe cleaning fluid 730. The transducer 750 produces ultrasonicvibrations 755 into the intermediately leached PDC cutter 500 whichpromotes the removal of the by-product materials 398 from the PCDcutting table 510 back into the cleaning fluid 730. The operatingfrequency of the transducer 750 and the intensity of the elastic wavesemitted from the transducer 750 can be adjusted to maximize the amountof vibrations 755 delivered to the PCD cutting table 510. Furthermore,the ultrasonic vibrations 755 mechanically improve the cleaning fluid730 circulation rate into and out of the interstitial spaces 212 (FIG.2), thereby providing fresh cleaning fluid 730 into the interstitialspaces 212 (FIG. 2). Once the by-product material 398 is removed fromthe PCD cutting table 510, the cleaning fluid 730 is able to proceeddeeper into the PCD cutting table 510 and dissolve more by-productmaterials 398 located within additional interstitial voids 212 (FIG. 2).Upon at least some of the by-product materials 398 being removed fromthe leached portion 554, the intermediately leached PDC cutter 500becomes the intermediately cleaned leached PDC cutter 600 (FIG. 6).Although a single intermediately leached PDC cutter 500 is shown to beimmersed in the cleaning fluid 730, several intermediately leached PDCcutters 500 can be immersed into the cleaning fluid 730 to remove theby-product materials 398 from each of the PCD cutting tables 510simultaneously in other exemplary embodiments.

In another example, FIG. 8 is a cross-sectional view of a by-productsremoval apparatus 800 in accordance with another exemplary embodiment.The by-products removal apparatus 800 is similar to the by-productsremoval apparatus 700 (FIG. 7) except that the transducer 750 of theby-products removal apparatus 800 is submerged within the cleaning fluid730. The transducer 750 transmits ultrasonic vibrations 755 into thecleaning fluid 730, which then transmits the vibrations 755 into the PCDcutting table 510. As previously mentioned, the ultrasonic vibrations755 facilitate removal of the by-product materials 398, or salt, withinthe interstitial void 212 (FIG. 2) and increase the recirculation rateof the fresh cleaning fluid 730 into the PCD cutting table 510. Thus,the by-product material 398 removal rate is substantially increasedusing the transducer 750. Alternatively, the transducer 750 is coupledto a portion of the immersion tank 720. The other exemplary embodimentsand/or modifications as described with respect to FIG. 7 above areapplicable to the present exemplary embodiment.

In another example, FIG. 9 is a cross-sectional view of a by-productsremoval apparatus 900 in accordance with another exemplary embodiment.The by-products removal apparatus 900 is similar to the by-productsremoval apparatus 700 (FIG. 7) except that the cavity 726 of theimmersion tank 720 is covered by a lid 990 in the by-products removalapparatus 900. In certain exemplary embodiments, the lid 990 provides aseal to the cavity 726, thereby allowing the cavity 726 to bepressurized and the cleaning fluid 730 to be heated at highertemperatures, such as above 100° C. These higher temperatures increasethe cleaning rate of the by-products materials 398 (FIG. 5). A gasket(not shown) positioned between the lid 990 and the immersion tank 720can be used to facilitate providing the seal. The sealed lid 990 and theimmersion tank 720 collectively form the pressurizable vessel 910. Inthe exemplary embodiments that use the lid 990, the power source 760 canbe coupled to the lid 990 via a clamp 930, can be positioned outside thepressurizable vessel 910 as long as the pressurized vessel 910 providesa port (not shown) to electrically couple the power source 760 to thetransducer 750, or can be integrated with the transducer 750. The otherexemplary embodiments and/or modifications as described with respect toFIG. 7 above are applicable to the present exemplary embodiment.

In yet another example, FIG. 10 is a cross-sectional view of aby-products removal apparatus 1000 in accordance with another exemplaryembodiment. The by-products removal apparatus 1000 is similar to theby-products removal apparatus 800 (FIG. 8) except that the cavity 726 ofthe immersion tank 720 is covered by a lid 990 in the by-productsremoval apparatus 1000. In certain exemplary embodiments, the lid 990provides a seal to the cavity 726, thereby allowing the cavity 726 to bepressurized and the cleaning fluid 730 to be heated at highertemperatures, such as above 100° C. These higher temperatures increasethe cleaning rate of the by-products materials 398 (FIG. 5). A gasket(not shown) positioned between the lid 990 and the immersion tank 720can be used to facilitate providing the seal. The sealed lid 990 and theimmersion tank 720 collectively form the pressurizable vessel 910. Inthe exemplary embodiments that use the lid 990, the power source 760 canbe coupled to the lid 990 via a clamp 930, can be positioned outside thepressurizable vessel 910 as long as the pressurized vessel 910 providesa port (not shown) to electrically couple the power source 760 to thetransducer 750, or can be integrated with the transducer 750. The otherexemplary embodiments and/or modifications as described with respect toFIG. 7 and above are applicable to the present exemplary embodiment.

According to some exemplary embodiments, the effectiveness of theby-product materials removal process is optionally verified. In theevent that the intermediately cleaned leached PDC cutter 600 is notcleaned to a desired level, the intermediately cleaned leached PDCcutter 600 is further cleaned in either the same cleaning fluid 730 or afresh cleaning fluid 730 until the desired level is reached. Thus,multiple cleaning cycles are performed on the intermediately leached PDCcutter 500 in some exemplary embodiments to fully, or substantially,remove the by-product materials 398. FIG. 11 is a flowchart depicting aby-product materials removal verification method 1100 in accordance withan exemplary embodiment of the present invention. Although FIG. 11 showsa series of steps depicted in a certain order, the order of one or moresteps can be rearranged, combined into fewer steps, and/or separatedinto more steps than that shown in other exemplary embodiments.Referring to FIG. 11, the by-product materials removal verificationmethod 1100 begins at step 1110. Upon starting at step 1110, theby-product materials removal verification method 1100 proceeds to step1120. At step 1120, one or more intermediately leached PDC cutters areobtained. According to certain exemplary embodiments, eachintermediately leached PDC cutter includes a polycrystalline structurehaving a leached portion and an unleached layer. The leached portionincludes one or more by-product materials. These intermediately leachedPDC cutters have been described above in detail with respect to FIG. 5and therefore are not described again for the sake of brevity.

The by-product materials removal verification method 1100 proceeds tostep 1130. At step 1130, at least a portion of the by-product materialsfrom the intermediately leached PDC cutter is removed thereby forming anintermediately cleaned leached PDC cutter. The by-product materials areremoved from the intermediately leached PDC cutter using the by-productsremoval apparatus 700 (FIG. 7), the by-products removal apparatus 800(FIG. 8), the by-products removal apparatus 900 (FIG. 9), theby-products removal apparatus 1000 (FIG. 10), or some other by-productsremoval apparatus that becomes known to other people having ordinaryskill in the art with the benefit of the present disclosure. Aspreviously described, a cleaning fluid and a transducer, according tosome exemplary embodiments, are used to remove at least a portion of theby-product materials from the intermediately leached PDC cutter.

The by-product materials removal verification method 1100 proceeds tostep 1140. At step 1140, at least one capacitance value for each of theintermediately cleaned leached PDC cutter is measured. Theintermediately cleaned leached PDC cutter has been described above indetail with respect to FIG. 6 and therefore is not described again forthe sake of brevity. The capacitance value is determined using acapacitance measuring system, as described below.

FIG. 12 is a schematic view of a capacitance measuring system 1200 inaccordance to one exemplary embodiment of the present invention.Referring to FIG. 12, the capacitance measuring system 1200 includes acapacitance measuring device 1210, the intermediately cleaned leachedPDC cutter 600, a first wire 1230, and a second wire 1240. In otherexemplary embodiments, the intermediately leached PDC cutter 500 (FIG.5) is used in lieu of the intermediately cleaned leached PDC cutter 600.Although certain components have been enumerated as being included inthe capacitance measuring system 1200, additional components areincluded in other exemplary embodiments. Additionally, although thedescription provided below has been provided with respect to theintermediately cleaned leached PDC cutter 600, a different component,such as the PCD cutting table 610 alone or other component that includesanother type of intermediately clean leached polycrystalline structureor intermediately leached polycrystalline structure, is used in lieu ofthe intermediately cleaned leached PDC cutter 600. The cleaned leachedPDC cutter 600 has been previously described with respect to FIG. 6 andis not repeated again herein for the sake of brevity.

The capacitance measuring device 1210 is a device that measures thecapacitance of an energy storage device, which is the intermediatelycleaned leached PDC cutter 600, or the intermediately leached PDC cutter500 (FIG. 5), in the instant exemplary embodiment. Capacitance is ameasure of the amount of electric potential energy stored, or separated,for a given electric potential. A common form of energy storage deviceis a parallel-plate capacitor. In the instant exemplary embodiment, theintermediately cleaned leached PDC cutter 600 is an example of theparallel-plate capacitor. The capacitance of the energy storage deviceis typically measured in farads, or nanofarads.

One example of the capacitance measuring device 1210 is a multi-meter;however, other capacitance measuring devices known to people havingordinary skill in the art are used in one or more alternative exemplaryembodiments. The multi-meter 1210 includes a positionable dial 1212, aplurality of measurement settings 1214, a display 1216, a positiveterminal 1218, and a negative terminal 1219. According to some exemplaryembodiments, the positionable dial 1212 is rotatable in a clockwiseand/or counter-clockwise manner and is set to one of several availablemeasurement settings 1214. In the instant exemplary embodiment, thepositionable dial 1212 is set to a nanofaraday setting 1215 so that themulti-meter 1210 measures capacitance values. The display 1216 isfabricated using polycarbonate, glass, plastic, or other known suitablematerial and communicates a measurement value, such as a capacitancevalue, to a user (not shown) of the multi-meter 1210. The positiveterminal 1218 is electrically coupled to one end of the first wire 1230,while the negative terminal 1219 is electrically coupled to one end ofthe second wire 1240.

The first wire 1230 is fabricated using a copper wire or some othersuitable conducting material or alloy known to people having ordinaryskill in the art. According to some exemplary embodiments, the firstwire 1230 also includes a non-conducting sheath (not shown) thatsurrounds the copper wire and extends from about one end of the copperwire to an opposing end of the cooper wire. The two ends of the copperwire are exposed and are not surrounded by the non-conducting sheath. Insome exemplary embodiments, an insulating material (not shown) alsosurrounds the copper wire and is disposed between the copper wire andthe non-conducting sheath. The insulating material extends from aboutone end of the non-conducting sheath to about an opposing end of thenon-conducting sheath. As previously mentioned, one end of the firstwire 830 is electrically coupled to the positive terminal 1218, whilethe opposing end of the first wire 1230 is electrically coupled to thecutting surface 512 of the intermediately cleaned leached PDC cutter600. The opposing end of the first wire 1230 is electrically coupled tothe cutting surface 512 in one of several methods. In one example, thefirst wire 1230 is electrically coupled to the cutting surface 512 usingone or more fastening devices (not shown), such as a clamp, or using anequipment (not shown) that supplies a force to retain the first wire1230 in electrical contact with the cutting surface 512. In anotherexample, a clamp (not shown) is coupled to the opposing end of the firstwire 1230 and a conducting component (not shown), such as aluminum foil,is coupled to, or placed in contact with, the cutting surface 512. Theclamp is electrically coupled to the conducting component, therebyelectrically coupling the first wire 1230 to the cutting surface 512.Additional methods for coupling the first wire 1230 to the cuttingsurface 512 can be used in other exemplary embodiments.

The second wire 1240 is fabricated using a copper wire or some othersuitable conducting material or alloy known to people having ordinaryskill in the art. According to some exemplary embodiments, the secondwire 1240 also includes a non-conducting sheath (not shown) thatsurrounds the copper wire and extends from about one end of the copperwire to an opposing end of the cooper wire. The two ends of the copperwire are exposed and are not surrounded by the non-conducting sheath. Insome exemplary embodiments, an insulating material (not shown) alsosurrounds the copper wire and is disposed between the copper wire andthe non-conducting sheath. The insulating material extends from aboutone end of the non-conducting sheath to an opposing end of thenon-conducting sheath. As previously mentioned, one end of the secondwire 1240 is electrically coupled to the negative terminal 1219, whilethe opposing end of the second wire 1240 is electrically coupled to abottom surface 364, which is similar to the bottom surface 154 (FIG. 1),of the intermediately cleaned leached PDC cutter 600. The second wire1240 is electrically coupled to the bottom surface 364 in a similarmanner as the first wire 1230 is electrically coupled to the cuttingsurface 512.

Hence, a circuit 1205 is completed using the multi-meter 1210, the firstwire 1230, the intermediately cleaned leached PDC cutter 600, and thesecond wire 1240. The current is able to flow from the positive terminal1218 of the multi-meter 1210 to the cutting surface 512 of theintermediately cleaned leached PDC cutter 600 through the first wire1230. The current then flows through the intermediately cleaned leachedPDC cutter 600 to the bottom surface 364 of the intermediately cleanedleached PDC cutter 600. When the multi-meter 1210 is turned on, avoltage differential exists between the cutting surface 512 and thebottom surface 364. The current then flows from the bottom surface 364to the negative terminal 1219 of the multi-meter 1210 through the secondwire 1240. The capacitance measurement of the intermediately cleanedleached PDC cutter 600 is determined when the value displayed on thedisplay 1216 reaches a peak value or remains constant for a period oftime. The use, analyzing of the results, and other information regardingthe capacitance measuring system 1200 is described in U.S. patentapplication Ser. No. 13/401,188, entitled “Use of Capacitance to AnalyzePolycrystalline Diamond” and filed on Feb. 21, 2012, which has beenincorporated by reference herein.

FIG. 13 is a schematic view of a capacitance measuring system 1300 inaccordance to another exemplary embodiment of the present invention.Referring to FIG. 13, the capacitance measuring system 1300 includes thecapacitance measuring device 1210, the intermediately cleaned leachedPDC cutter 600, the first wire 1230, the second wire 1240, a firstconducting material 1310, a second conducting material 1320, a firstinsulating material 1330, a second insulating material 1340, and anArbor Press 1350. In certain alternative exemplary embodiments, theintermediately leached PDC cutter 500 (FIG. 5) is used in lieu of theintermediately cleaned leached PDC cutter 600. Although certaincomponents have been enumerated as being included in the capacitancemeasuring system 1300, additional components are included in otherexemplary embodiments. Further, although certain components have beenenumerated as being included in the capacitance measuring system 1300,alternative components having similar functions as the enumeratedcomponents are used in alternative exemplary embodiments. Additionally,although the description provided below has been provided with respectto the intermediately cleaned leached PDC cutter 600, a differentcomponent, such as the PCD cutting table 610 (FIG. 6) alone or othercomponent that includes another type of leached, or cleaned leached,polycrystalline structure, is used in lieu of the intermediately cleanedleached PDC cutter 600. The capacitance measuring device 1210, theintermediately cleaned leached PDC cutter 600, the first wire 1230, andthe second wire 1240 have been previously described and are not repeatedagain herein for the sake of brevity.

The first conducting material 1310 and the second conducting material1320 are similar to one another in certain exemplary embodiments, butare different in other exemplary embodiments. According to one exemplaryembodiment, the conducting materials 1310, 1320 are fabricated usingaluminum foil; however, other suitable conducting materials can be used.The first conducting material 1310 is positioned adjacently above and incontact with the cutting surface 512. The second conducting material1320 is positioned adjacently below and in contact with the bottomsurface 364. The first conducting material 1310 and the secondconducting material 1320 provide an area to which the first wire 1230and the second wire 1240, respectively, make electrical contact.Additionally, the first conducting material 1310 and the secondconducting material 1320 assist in minimizing contact resistance withthe cutting surface 512 and the bottom surface 364, respectively, whichis discussed in further detail below. In certain exemplary embodiments,the first conducting material 1310 and the second conducting material1320 are the same shape and size; while in other exemplary embodiments,one of the conducting materials 1310, 1320 is a different shape and/orsize than the other conducting material 1310, 1320.

The first insulating material 1330 and the second insulating material1340 are similar to one another in certain exemplary embodiments, butare different in other exemplary embodiments. According to one exemplaryembodiment, the insulating materials 1330, 1340 are fabricated usingpaper; however, other suitable insulating materials, such as rubber, canbe used. The first insulating material 1330 is positioned adjacentlyabove and in contact with the first conducting material 1310. The secondinsulating material 1340 is positioned adjacently below and in contactwith the second conducting material 1320. The first insulating material1330 and the second insulating material 1340 provide a barrier to directcurrent flow only through a circuit 1305, which is discussed in furtherdetail below. In certain exemplary embodiments, the first insulatingmaterial 1330 and the second insulating material 1340 are the same shapeand size; while in other exemplary embodiments, one of the insulatingmaterials 1330, 1340 is a different shape and/or size than the otherinsulating material 1330, 1340. Additionally, in certain exemplaryembodiments, the insulating materials 1330, 1340 is larger in size thanits corresponding conducting material 1310, 1320. However, one or moreof the insulating materials 1330, 1340 is either larger or smaller thanits corresponding conducting material 1310, 1320 in alternativeexemplary embodiments.

The Arbor Press 1350 includes an upper plate 1352 and a base plate 1354.The upper plate 1352 is positioned above the base plate 1354 and ismovable towards the base plate 1354. In other exemplary embodiments, thebase plate 1354 is movable towards the upper plate 1352. The firstinsulating material 1330, the first conducting material 1310, theintermediately cleaned leached PDC cutter 600, the second conductingmaterial 1320, and the second insulating material 1340 are positionedbetween the upper plate 1352 and the base plate 1354 such that thesecond insulating material 1340 is positioned adjacently above and incontact with the base plate 1354. The upper plate 1352 is moved towardsthe base plate 1354 until the upper plate 1352 applies a downward load1353 onto the cutting surface 512 of the intermediately cleaned leachedPDC cutter 600. When the downward load 1353 is applied, the firstconducting material 1310 is deformed and adapted to the rough and verystiff cutting surface 512, thereby minimizing contact resistance betweenthe first conducting material 1310 and the cutting surface 512 andgreatly improving the capacitance measurement consistency. At this time,the base plate 1354 also applies an upward load 1355 onto the bottomsurface 364 of the intermediately cleaned leached PDC cutter 600. Whenthe upward load 1355 is applied, the second conducting material 1320 isdeformed and adapted to the rough and very stiff bottom surface 364,thereby minimizing contact resistance between the second conductingmaterial 1320 and the bottom surface 364 and greatly improving thecapacitance measurement consistency. In certain exemplary embodiments,the downward load 1353 is equal to the upward load 1355. The downwardload 1353 and the upward load 1355 is about one hundred pounds; however,these loads 1353, 1355 range from about two pounds to about a criticalload. The critical load is a load at which the intermediately cleanedleached PDC cutter 600 is damaged when applied thereto.

In one exemplary embodiment, the second insulating material 1340 ispositioned on the base plate 1354, the second conducting material 1320is positioned on the second insulating material 1340, the intermediatelycleaned leached PDC cutter 600 is positioned on the second conductingmaterial 1320, the first conducting material 1310 is positioned on theintermediately cleaned leached PDC cutter 600, and the first insulatingmaterial 1330 is positioned on the first conducting material 1310. Theupper plate 1352 is moved towards the first insulating material 1330until the downward load 1353 is applied onto the intermediately cleanedleached PDC cutter 600. In an alternative exemplary embodiment, one ormore components, such as the first insulating material 1330 and thefirst conducting material 1310, are coupled to the upper plate 1352prior to the upper plate 1352 being moved towards the base plate 1354.Although an Arbor Press 1350 is used in the capacitance measuring system1300, other equipment capable of delivering equal and opposite loads toeach of the cutting surface 512 and the bottom surface 364 of theintermediately cleaned leached PDC cutter 600 can be used in otherexemplary embodiments.

One end of the first wire 1230 is electrically coupled to the positiveterminal 1218 of the multi-meter 1210, while the opposing end of thefirst wire 1230 is electrically coupled to the first conducting material1310, which thereby becomes electrically coupled to the cutting surface512 of the intermediately cleaned leached PDC cutter 600. In oneexemplary embodiment, a clamp 1390 is coupled to the opposing end of thefirst wire 1230 which couples the first wire 1230 to the firstconducting material 1310. One end of the second wire 1240 iselectrically coupled to the negative terminal 1219 of the multi-meter1210, while the opposing end of the second wire 1240 is electricallycoupled to the second conducting material 1320, which thereby becomeselectrically coupled to the bottom surface 364 of the intermediatelycleaned leached PDC cutter 600. In one exemplary embodiment, a clamp(not shown), similar to clamp 1390, is coupled to the opposing end ofthe second wire 1240, which couples the second wire 1240 to the secondconducting material 1320. Hence, the circuit 1305 is completed using themulti-meter 1210, the first wire 1230, the first conducting material1310, the intermediately cleaned leached PDC cutter 600, the secondconducting material 1320, and the second wire 1340. The current is ableto flow from the positive terminal 1218 of the multi-meter 1210 to thecutting surface 512 of the intermediately cleaned leached PDC cutter 600through the first wire 1230 and the first conducting material 1310. Thecurrent then flows through the intermediately cleaned leached PDC cutter600 to the bottom surface 364 of the intermediately cleaned leached PDCcutter 600. When the multi-meter 1210 is turned on, a voltagedifferential exists between the cutting surface 512 and the bottomsurface 364. The current then flows from the bottom surface 364 to thenegative terminal 1219 of the multi-meter 1210 through the secondconducting material 1320 and the second wire 1240. The first insulatingmaterial 1330 and the second insulating material 1340 prevent thecurrent from flowing into the Arbor Press 1350. The capacitancemeasurement of the intermediately cleaned leached PDC cutter 600 isdetermined when the value displayed on the display 1216 reaches a peakvalue or remains constant for a period of time. The use, analyzing ofthe results, and other information regarding the capacitance measuringsystem 1300 is described in U.S. patent application Ser. No. 13/401,188,entitled “Use of Capacitance to Analyze Polycrystalline Diamond” andfiled on Feb. 21, 2012, which has been incorporated by reference herein.

Referring back to FIG. 11, the by-product materials removal verificationmethod 1100 proceeds to step 1150. At step 1150, removal of at least aportion of the by-product materials from the intermediately cleanedleached PDC cutter and measuring at least one capacitance value for atleast one of the intermediately cleaned leached PDC cutter is continueduntil the capacitance value is at a stable lower limit capacitancevalue. The removal of at least a portion of the by-product materials hasbeen described with respect to step 1130 and the measuring of thecapacitance values has been described with respect to step 1140. Thestable lower limit capacitance value is the capacitance value of anintermediately cleaned leached PDC cutter at which the measuredcapacitance value does not further decrease upon further removal ofby-product materials from the intermediately cleaned leached PDC cutter,i.e. further cleaning of the intermediately cleaned leached PDC cutter.The stable lower limit capacitance value is illustrated in FIG. 14.

FIG. 14 is a data scattering chart 1400 that shows the measuredcapacitance values 1411 for a plurality of intermediately leached and/orintermediately cleaned cutters 500, 600 at different cleaning cyclesaccording to an exemplary embodiment. Referring to FIG. 14, the datascattering chart 1400 includes a cutter number axis 1420 and acapacitance axis 1410. The cutter number axis 1420 includes the numberof the cutters 1422 tested along with a cleaning cycle number 1423. Asshown, the first set of cutter numbers 1424 has not been cleaned ofby-product materials 398 (FIG. 5), the second set of cutter numbers 1425has been cleaned of by-product materials 398 (FIG. 5) through a firstcleaning cycle 1427, and the third set of cutter numbers 1426 has beencleaned of by-product materials 398 (FIG. 5) through a second cleaningcycle 1428. The capacitance axis 1410 includes values for the measuredcapacitance 1411. A capacitance data point 1430 is obtained by measuringthe capacitance of the intermediately leached and/or intermediatelycleaned cutter 500, 600, or intermediately leached and/or intermediatelycleaned component, using the capacitance measuring system 1200 (FIG.12), the capacitance measuring system 1300 (FIG. 13), or a similar typesystem. Each capacitance data point 1430 for each cutter number 1422,with its respective cleaning cycle number 1423, is plotted on the datascattering chart 1400. Each cutter number 1422 has its capacitancemeasured a plurality of times. In some exemplary embodiments, fivecapacitance data points 1430 are obtained for each cutter number 1422,however, the number of measurements is greater or fewer in otherexemplary embodiments. In some exemplary embodiments, a twenty-fivepercentile marking 1450, a fifty percentile marking 1452 (or average),and a seventy-five percentile marking 1454 are shown in the chart 1400for each cutter number 1422. The area between the twenty-five percentilemarking 1450 and the seventy-five percentile marking 1454 is shaded. Theamount of data scattering is ascertained using this data scatteringchart 1400 and can be one or more of a differential between the highestand lowest capacitance measurements 1411 for each cutter number 1422, arange between the twenty-five percentile marking 1450 and theseventy-five percentile marking 1454, or some similar observation madefrom the data scattering chart 1400.

According to FIG. 14, the first set of cutter numbers 1424, which hasnot yet been cleaned, shows a larger data scattering of capacitancevalues 1411 than when compared to the second set of cutter numbers 1425,which has been cleaned once for one hour using the by-products removalapparatus 700 (FIG. 7), the by-products removal apparatus 800 (FIG. 8),the by-products removal apparatus 900 (FIG. 9), or the by-productsremoval apparatus 1000 (FIG. 10). Further, the second set of cutternumbers 1425, which has been cleaned once for one hour using theby-products removal apparatus 700 (FIG. 7), the by-products removalapparatus 800 (FIG. 8), the by-products removal apparatus 900 (FIG. 9),or the by-products removal apparatus 1000 (FIG. 10), shows a larger datascattering of capacitance values 1411 than when compared to the thirdset of cutter numbers 1426, which has been cleaned a second time foranother one hour using the by-products removal apparatus 700 (FIG. 7),the by-products removal apparatus 800 (FIG. 8), the by-products removalapparatus 900 (FIG. 9), or the by-products removal apparatus 1000 (FIG.10). The third set of cutter numbers 1426 exhibit a minimal, ornegligible, amount of data scattering of capacitance values 1411. Thus,the capacitance values 1411 of the third set of cutter numbers 1426 isthe stable lower limit capacitance value 1429 in this exemplaryembodiment. However, it is possible, that if the third set of cutternumbers 1426 was to undergo an additional cleaning cycle, thecapacitance values 1411 of the fourth set of cutter numbers (not shown)would be the stable lower limit capacitance value. When the stable lowerlimit capacitance value 1429 is reached, i.e. there is minimal to nodata scattering of capacitance values 1411, the intermediately cleanedleached PDC cutters 600 are effectively cleaned and verified as such.

Referring back to FIG. 11, the by-product materials removal verificationmethod 1100 proceeds to step 1160. At step 1160, the by-productmaterials removal verification method 1100 ends.

Referring back to FIG. 4, the leaching method 400 proceeds to step 450.At step 450, the leaching process and the cleaning process continueiteratively and alternatingly on the intermediately cleaned leached PDCcutter 600 (FIG. 6) until the depth of the leached portion 554 (FIG. 5)reaches a desired leaching depth 353 (FIG. 3). In some exemplaryembodiments, however, the leaching process and the cleaning process arenot performed alternatingly, but one or more processes are performedconsecutively before the other process is performed. Once the desiredleaching depth 353 is reached, a cleaned leached PDC cutter 1500 (FIG.15) is formed. As previously mentioned, cleaning the intermediatelyleached PDC cutter 500 (FIG. 5) to form the intermediately cleanedleached PDC cutter 600 (FIG. 6) allows the subsequent leaching processthat is performed to be at a faster rate than if the intermediatelyleached PDC cutter 500 (FIG. 5) was not cleaned. Hence, the cleanedleached PDC cutter 1500 (FIG. 15) is formed in a shorter duration thanif it were to be formed using a single leaching process and a singlecleaning process on the PDC cutter 100 (FIG. 1).

FIG. 15 shows a cross-sectional view of the cleaned leached PDC cutter1500 having a PCD cutting table 1510 that has been leached and cleanedto the desired leaching depth 353 in accordance with an exemplaryembodiment. The cleaned leached PDC cutter 1500 has been exposed to twoor more leaching cycles and at least one cleaning cycle. Referring toFIG. 15, the cleaned leached PDC cutter 1500 includes the PCD cuttingtable 1510 coupled to the substrate 350. The substrate 350 has beenpreviously described above with respect to FIG. 3 and therefore is notdescribed again for the sake of brevity. The PCD cutting table 1510 issimilar to the PCD cutting table 310 (FIG. 3), but has had at least aportion of the by-product materials 398 removed from a cleaned leachedlayer 1554. The cleaned leached layer 1554 is similar to leached layer354 (FIG. 3) except that at least a portion of the by-product materials398 is removed from the leached layer 354 (FIG. 3) to form the cleanedleached layer 1554. Thus, PCD cutting table 1510 includes the cleanedleached layer 1554 and the unleached layer 356 which is disposed betweenthe cleaned leached layer 1554 and the substrate 350. The cleanedleached layer 1554 extends from the cutting surface 312, which has beendescribed above with respect to FIG. 3, towards the opposing surface314, which also has been described with respect to FIG. 3. In thecleaned leached layer 1554, at least a portion of the cobalt 214 hasbeen removed from within the interstitial spaces 212 (FIG. 2) using atleast one leaching process mentioned above when compared to the PCDcutting table 110 (FIG. 1). Thus, the cleaned leached layer 1554 hasbeen leached to the desired leaching depth 353. However, as previouslymentioned above, one or more by-product materials 398 were formed anddeposited within some of the interstitial spaces 212 (FIG. 2) in theleached layer 354 (FIG. 3) during the leaching process. However, atleast a portion of these by-product materials 398 are removed from theleached layer 354 (FIG. 3), thereby forming leached layer 1554. Theprocess of removing the by-product materials 398 from the leached layer354 (FIG. 3) has been described above and is not repeated again herein.The unleached layer 356 has been previously described with respect toFIG. 3 and therefore is not repeated for the sake of brevity. Althoughthe boundary line 355 is formed between the cleaned leached layer 1554and the unleached layer 356 and is depicted as being substantiallylinear, the boundary line 355 can be non-linear.

Referring back to FIG. 4, the leaching method proceeds to step 460. Atstep 460, the leaching method 400 ends.

A cleaned leached PDC cutter, which is substantially free of by-productmaterials, or catalyst metal salts, has a superior wear abrasionresistance with an increased thermal stability. Thus, the apparatus andmethods disclosed herein minimizes the detrimental effects of theleaching reaction by-product materials. Further, a cleaning cycleoccurring intermittently between successive leaching cycles allows thesubsequent leaching cycle to proceed at a faster rate. Removing at leasta portion of the by-product materials trapped within the leached portionhas a beneficial effect of allowing the leaching solution to infiltrateinto the polycrystalline structure faster and deeper. Although theconventional leaching method allows the leaching depth to reach about300 microns only after long treatment periods, which are at times inexcess of several days, the leaching method 400 allows the leachingdepths to be reached in much shorter time periods or to reach the entirethickness of the polycrystalline structure in a few day. Conventionalleaching process typically takes several weeks of treatment time whenleaching the entire depth of the polycrystalline structure.

Although each exemplary embodiment has been described in detail, it isto be construed that any features and modifications that are applicableto one embodiment are also applicable to the other embodiments.Furthermore, although the invention has been described with reference tospecific embodiments, these descriptions are not meant to be construedin a limiting sense. Various modifications of the disclosed embodiments,as well as alternative embodiments of the invention will become apparentto persons of ordinary skill in the art upon reference to thedescription of the exemplary embodiments. It should be appreciated bythose of ordinary skill in the art that the conception and the specificembodiments disclosed may be readily utilized as a basis for modifyingor designing other structures or methods for carrying out the samepurposes of the invention. It should also be realized by those ofordinary skill in the art that such equivalent constructions do notdepart from the spirit and scope of the invention as set forth in theappended claims. It is therefore, contemplated that the claims willcover any such modifications or embodiments that fall within the scopeof the invention.

1. A leached cutter, comprising: a substrate; and a cutting tablecoupled to a surface of the substrate, the cutting table comprising acutting surface, a side surface extending from the perimeter of thecutting surface towards a perimeter of the surface of the substrate, anda polycrystalline structure formed therethrough, the polycrystallinestructure, comprising: an unleached layer positioned adjacent to thesubstrate and comprising a plurality of catalyst material depositedtherein; and a leached, layer positioned adjacent to the unleachedlayer, the leached layer having at least a portion of the catalystmaterial and a portion of a by-product material removed from therein,wherein the leached layer is formed by the method comprising: performinga leaching process on the polycrystalline structure until, at least aportion of the catalyst material is removed from an intermediateleaching depth of the polycrystalline structure, the leaching processforming the by-product material that deposited within the intermediateleaching depth of the polycrystalline structure; performing a cleaningprocess on the polycrystalline structure until at least a portion of theby-product, material is removed from the intermediate leaching depth ofthe polycrystalline structure; and continuing iteratively performing theleaching process and performing the cleaning process on thepolycrystalline structure until the intermediate leaching depth reachesa desired leaching depth, wherein a different intermediate leachingdepth is reached during each successive leaching process and eachdifferent intermediate leaching depth progresses towards the desiredleaching depth, and wherein the desired leaching depth is greater thanat least one intermediate leaching depth.
 2. The leached cutter of claim1, wherein, continuing iteratively performing the leaching process andperforming the cleaning process on the polycrystalline structure untilthe intermediate leaching depth reaches a desired leaching depthcomprises performing the leaching process last.
 3. The leached cutter ofclaim 1, wherein continuing iteratively performing the leaching processand performing the cleaning process on the polycrystalline structureuntil the intermediate leaching depth reaches a desired leaching depthcomprises performing the cleaning process last.
 4. The leached cutter ofclaim 1, wherein continuing iteratively performing the leaching processand performing the cleaning process on the polycrystalline structurecomprises performing the leaching process and performing the cleaningprocess on the polycrystalline structure in an alternating manner. 5.The leached cutter of claim 1, wherein the leaching process comprisesimmersing at least a portion of the polycrystalline structure into anacidic solution,
 6. The leached cutter of claim 1, wherein the cleaningprocess comprises immersing at least a portion of the polycrystallinestructure into a cleaning fluid.
 7. The leached cutter of claim 6,wherein the cleaning fluid comprises de-ionized water.
 8. The leachedcutter of claim 1, wherein the intermediate depth is measured from atleast a portion of the cutting surface towards an interior of thepolycrystalline structure.
 9. The leached carter of claim 1, wherein theintermediate depth is measured from at least a portion of the sidesurface towards an interior of the polycrystalline structure,
 10. Theleached cutter of claim 1, wherein the cleaning process is performedfrom at least, a portion of the side surface.
 11. The leached cutter ofclaim 1, wherein the cleaning process is performed from at least aportion of the cutting surface.
 12. A leaching method for removing atleast a portion of a catalyst material from within a polycrystallinestructure, the catalyst material being removed from the polycrystallinestructure to a desired leaching depth within the polycrystallinestructure, the method comprising: obtaining a component comprising apolycrystalline structure, the poly crystalline structure comprising afirst end, a second end opposite the first end, and a side surfaceextending from the perimeter of the first end to a perimeter of thesecond end; performing a leaching process on the polycrystallinestructure until at least a portion of the catalyst material is removedfrom an intermediate leaching depth, of the polycrystalline structurethe leaching process forming at least some by-product materialsdeposited within the intermediate leaching depth of the polycrystallinestructure, the intermediate leaching depth being measured from a surfaceof the polycrystalline structure; performing a cleaning process on thepolycrystalline structure until at least a portion of the by-productmaterials is removed from the intermediate leaching depth of thepolycrystalline structure;, and continuing iteratively performing theleaching process and performing the cleaning process on foepolycrystalline structure until the intermediate leaching depth reachesa desired leaching depth, the desired leaching depth being measured fromthe surface of the polycrystalline structure, wherein a differentintermediate leaching depth is reached during each leaching process andeach different intermediate leaching depth progresses towards thedesired leaching depth, and wherein the desired leaching depth isgreater than at least one intermediate leaching depth.
 13. The leachingmethod of claim 11, wherein the surface of the polycrystalline structurecomprises, at least a portion of the side surface of the polycrystallinestructure.
 14. The leaching method of claim 11, wherein the surface ofthe polycrystalline structure comprises at least a portion of the firstend of the polycrystalline structure.
 15. The leaching method of claim11, wherein continuing iteratively performing the leaching process andperforming the cleaning process on the polycrystalline structure untilthe intermediate leaching depth reaches a desired leaching depthcomprises performing the leaching process last.
 16. The leaching methodof claim 11, wherein continuing iteratively performing the leachingprocess arid performing the cleaning process on the polycrystallinestructure until the intermediate leaching depth reaches a desiredleaching depth comprises performing the cleaning process last.
 17. Theleaching method of claim 11, wherein the intermediate depth is measuredfrom at least a portion of the cutting surface towards an interior ofthe polycrystalline structure,
 18. The leaching method of claim 11,wherein the intermediate depth is measured from at least a portion ofthe side surface towards an interior of the polycrystalline structure.19. The leaching method of claim 11, wherein the cleaning process isperformed from at least a portion of the side surface.
 20. The leachingmethod of claim 11, wherein the cleaning process is performed from atleast a portion of the cutting surface.
 21. A drill bit, comprising: aleached cutter, comprising: a substrate; and a cutting table coupled toa surface of the substrate, the cutting table comprising a cuttingsurface, a side surface extending from the perimeter of the cuttingsurface towards a perimeter of the surface of the substrate, and apolycrystalline structure formed therethrough, the polycrystallinestructure, comprising: an unleached layer positioned adjacent to thesubstrate and comprising a plurality of catalyst material depositedtherein; and a leached layer positioned adjacent to the unleached layer,the leached layer having at least a portion of the catalyst material anda portion of a by-product material removed from therein, wherein theleached layer is formed by the method comprising: performing a leachingprocess on the polycrystalline structure until at least a portion of thecatalyst material is removed from an intermediate leaching depth of thepolycrystalline structure, the leaching process forming the by-productmaterial that deposited within the intermediate leaching depth of thepolycrystalline structure; performing a cleaning process on thepolycrystalline structure until at least a portion of the by-productmaterial is removed from the intermediate leaching depth of thepolycrystalline structure; and continuing iteratively performing theleaching process and performing the cleaning process on thepolycrystalline structure until the intermediate leaching depth reachesa desired leaching depth, wherein a different intermediate leachingdepth is reached during each successive leaching process and eachdifferent intermediate leaching depth progresses towards the desiredleaching, depth, and wherein the desired leaching depth is greater thanat least one intermediate leaching depth.
 22. The drill bit of claim 21,wherein continuing iteratively performing the leaching process andperforming the cleaning process on the polycrystalline structure untilthe intermediate leaching depth reaches a desired leaching depthcomprises performing the leaching process last.
 23. The drill bit ofclaim 21, wherein continuing iteratively performing the leaching processand performing the cleaning process on the polycrystalline structureuntil the intermediate leaching depth reaches a desired leaching depthcomprises performing the cleaning process last
 24. The drill bit ofclaim 21, wherein the intermediate depth is measured from at least aportion of the cutting surface towards an interior of thepolycrystalline structure.
 25. The drill bit of claim 21, wherein theintermediate depth is measured from at least a portion of the sidesurface towards an interior of the polycrystalline structure.
 26. Thedrill bit of claim 21, wherein the cleaning process is performed from atleast a portion of the side surface.
 27. The drill bit of claim 21,wherein the cleaning process is performed from-at least a portion of thecutting surface.